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FRITO LAY & STOP Training

DuPont™ STOP™

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FRITO LAY & STOP Training

• ABOUT PEPSICO

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FRITO LAY & STOP Training

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FRITO LAY & STOP Training

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In the Beginning…

•  History of Safety School –  Started in 2004

•  Each site had its own •  Aberdeen’s (STARS – Safety Training At Risks Systems)

–  In 06/07 combined 3 FL sites programs •  (Aberdeen, York, Williamsport)

–  Designed for Repeat Offenders

–  Scheduled after work hours

–  Course was made up of 6 classes •  Ranging 1 ½ to 2 hours in length

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Pitfalls

•  DISADVANTAGES

•  VERY TIME CONSUMING

•  Attendance tracking nightmare

•  Make-up scheduling problems

•  Took forever to get Employees completed

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DuPont STOP Seminar

•  2008, started hearing good things about –  DuPont STOP training systems

•  Leadership and Safety bought into the idea

•  Ordered books and started classes –  Repeat offenders –  Management Team

•  GREAT RESULTS –  Implemented across site for all Employees

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What we did…

•  Establish Ground Rules

•  Set Agenda/Schedule

•  Who will Participate in Class

•  Make it a Comfortable Atmosphere

•  Customized to meet our needs

•  Outcome / Results

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Ground Rules

•  Ground Rules (may add additional for each class)

–  Start / Stop on Time –  Be Respectful

–  No use of Electronic Equipment –  No Side-Bar

–  Frequent Breaks/Stretching –  Vegas Rule

–  Dead Horse Rule

Daylene’s saying of the day:

• DON’T DWELL ON THE PAST, LEARN FROM IT

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What works for us…

•  AGENDA •  TWO – EIGHT HOUR DAYS

–  Day One •  Start 7:00 AM w/ Introductions and LED IN •  Unit I – 2 ½ hours •  Unit II – 1 ½ hours •  Unit III – 2 ½ hours

–  Wrap up and Discussion for Day One

–  Day Two •  Recap of Day One •  Unit III completion – 2 ¼ hours •  Unit IV – 2 hours •  Unit V – 2 Hours

–  Wrap up with LT and review of issues list

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No Debate…

•  PARTICIPATION –  MANDATORY

–  Cross Function of Employees

–  No more than 2 from the same Classification

–  Mix of At-Risk and Safety Minded Employees

–  All New Managers are Required during onboarding

–  Schedule classes every other Period •  (if time and dollars permit)

–  Invite Internal and External visitors

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Welcoming Setting…

•  Comfortable Settings •  Food

•  Furnish Breakfast (Bagels, Donuts, Fruit) •  Lunch/Drinks •  Candy/Prizes

•  Frequent Breaks –  Keep class going 75 minutes, MAX

•  Change up of Teams –  Pull numbers to pick teams

•  No 2 persons from same dept. or shift –  Re-org teams on Day Two

•  Visit Areas that you normally don’t work in •  Partners from another plant location

•  ALLOW TIME FOR PLENTY OF DISCUSSION

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Make it Fit your Site…

•  Customization –  Talk Job and Plant Specific Incidents

–  Add personal touches/stories

–  Show injuries and accidents from local papers

–  Share stories of tragedy from fellow co-workers

–  Utilize “YouTube” for Safety Shorts

Incidents/Injuries

• PREVENTABLE or

• NON-PREVENTABLE

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PERCENT PREVENTABLE? a)50% b)90% c)95% d)99%

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PERCENT PREVENTABLE? a)50% b)90% c)95% d)99%

(majority of the time, 100% by classroom vote)

OUTCOME & RESULTS

•  Since starting STOP Training

–  Over 250 Employees and Managers Graduated

–  Less than an 8% Return Rate for 2nd Round • Employees can complete 2 rounds of STOP Classroom

–  2 Day – 8 Hour Course

• 3rd Round is conducted by LT & Safety Manager –  (condensed version)

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COST

•  The Average Class cost: –  Wages

•  14 x $20.00 x 16 hours = $4,480.00

–  Food •  Breakfast, Snacks, Lunch = $500.00

–  Materials •  Initial Material Cost from DuPont •  Materials as needed

COST OF THE AVERAGE CLASS AROUND $4,980.00 plus Materials

Hidden cost (OT on the floor)

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What Questions might you have

about Safety School?

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